J. Bamboo and Rattan, Vol. 1, No. 2, pp.

119– 130 (2002)

Ó VSP 2002.
Also available online - www.vsppub.com

Bamboo composites: Material of the future

¤
ARUN K. BANSAL and S. S. ZOOLAGUD
Indian Plywood Industries Research and Training Institute, Post Bag 2273, Tumkur Road,
Bangalore 560 022, India

Abstract—Bamboo is an important renewable resource on which around 2.5 billion people all over
the world depend greatly for a wide range of products and livelihood. Bamboo has more than 1000
documented uses. About one billion people live in bamboo houses.
Bamboo, a tree-like grass, represented by about 1250 known species, is found in all regions of the
world: tropical, sub-tropical and temperate except in Europe and West Africa. Bamboo accounts for
approximately 25% and 20% of the total biomass respectively in the tropics and the sub-tropical areas.
Bamboo has several unique advantages, namely: (i) ability to rejuvenate degraded areas; (ii) grows
well in plantation models in harmony with other species, and hence there is no need for mono-culture;
(iii) short rotation cycle of 2– 5 years; and (iv) widely recognized traditional resource having quicker
acceptability.
Panel composites made from bamboo have great potential due to their better strength, dimensional
stability and other characteristics compared to panels made from several fast growing plantation
timbers. IPIRTI is the premier Indian R&D institution working for development for bamboo
composites. It has already developed technologies for several mat-based composites from bamboo
including Bamboo Mat Board (BMB), Bamboo Mat Veneer Composite (BMVC), and Bamboo
Mat Corrugated Sheets (BMCS). Whereas BMB and BMVC are being produced in some factories,
technology for BMCS is being scaled-up for industrial production. Works relating to development of
suitable application technologies and codes of practice are in also progress.
Additional positive aspects of bamboo-based panel materials are environmentallyfriendly reduction
of pressure on forests through wood substitution; it is people friendly as it uses traditional resources;
it enhances rural employment generation with participation of women and community development.
BMB technology developed at IPIRTI has been found to be an exemplary demonstration of
implementation of Agenda 21 by the International Selection Commission of EXPO-2000 and was
a registered Project around the World at the EXPO-2000 Hannover, Germany.
This paper discusses IPIRTI’s R&D efforts related to development of bamboo composites and their
relevance for people oriented development programs.

Key words: Bamboo composites; bamboo mat board; people and environmentally friendly technolo-
gies; wood substitution; employment generation; board properties.

¤
To whom correspondence should be addressed. E-mail cbdindia@vsnl.net; bansalka@vsnl.com
120 A. K. Bansal and S. S. Zoolagud

1. INTRODUCTION

India is the second most populated country in the world. With only about 1% of
the world’s forests, India supports 15% of world’s human population and 16% of
cattle population. The increasing needs of growing population and environmental
awareness have put severe restrictions on management of forest resources. This
has resulted in shortage of wood required in housing, transport and other sectors.
Several non-wood alternatives like metal and plastics have serious limitations on
account of high-energy requirements and non-bio-degradability. Moreover, long-
term sustainable supplies of products can be met by use of bio-mass based materials
alone [1]. To meet the increasing needs of the growing population a two-pronged
approach is necessary. First, it is necessary to evolve a policy for production and
efŽcient utilization of fast growing plantation woods [2]. Secondly, there is an
urgent need for development of materials and products from non-wood renewable
natural Žbers as sustainable and environment friendly alternatives to natural wood.
Bamboo, a fast growing tree-like grass, found in abundance in several provinces
of India is emerging as a material of high potential. Apart from being available in
natural forests, bamboo is also raised as plantations, both pure and as under planting,
and also in homesteads. Bamboo is also suitable for reforestation of degraded forest
and other wastelands as well as abandoned shifting lands.

2. BAMBOO COMPOSITES

It has now been realized that bamboo produces biomass faster and has superior
physical and mechanical properties compared to wood available from many fast
growing wood species. Some earlier studies have revealed that bamboo in panel
form is best suited to substitute wood in several applications. Development of
effective technologies to produce bamboo-based panel material is now an important
area of research not only in bamboo-growing countries but also in several other
countries.
The Žrst recorded production of panels from bamboo was during the Second
World War to make ply-bamboo by hot pressing woven bamboo sheets coated
with casein glues [3]. Almost at the same time research was initiated in India to
develop synthetic resin bonded bamboo mat board [4]. More than 30 types of panel
products, some of bamboo only and others of bamboo in combination with wood,
other lingo-cellulosic materials and inorganic materials have been developed using
bamboo either as woven mats or slabs / strips.

3. DEVELOPMENT OF BAMBOO COMPOSITES IN INDIA

In India, research efforts to make building boards from bamboo were initiated in the
mid-1950s at the Forest Research Institute, Dehra Dun, and several processes were
 Bamboo composites: Material of the future 121

evolved till early sixties [5] . However, industrial production of BMB in the country
started in the mid-1980s following the development of technology for making BMB
from the reed bamboos, Ochlandra travancorica and Ochlandra rheedi, by IPIRTI
under a project sponsored by the All India Handicrafts Board [6]. To improve
economic viability of the technology and enhance product acceptability, further
research was conducted at IPIRTI under the project ‘Bamboo Mat Board (India)’
funded by the International Development Research Center (IDRC), Canada and a
cost effective process was developed [7 – 10].
BMB technology has been further modiŽed for manufacturing Bamboo Mat
Veneer Composite (BMVC) made from bamboo mats in combination with veneers
from fast-growing plantation species for panels thicker than 6 mm.
BMB are made from manually woven bamboo mats and hence production of
BMB has immense employment generation potential particularly for rural and tribal
women who can virtually ‘weave money’ at home. Thus, while BMB technology
is environmentally sustainable it is also people friendly. The technology was
assessed to be an exemplary demonstration of implementation of Agenda 21 by the
International Selection Commission of EXPO-2000 and was registered as a Project
around the World at EXPO-2000 Hannover, Germany [11].
Seeing the potential of the BMB technology, the Building Material and Technol-
ogy Promotion Council (BMTPC) of India funded IPIRTI for a project for develop-
ment of technology for manufacturing bamboo mats corrugated sheeting (BMCS)
as an eco-friendly rooŽng material. Under this project, a pilot scale facility with
a one-day light hydraulic hot press Žtted with specially designed matching platens
has been established at the Institute. Full size (0.9 m £ 1.82 m) sheets manu-
factured at this pilot press have been used for rooŽng in several demonstration
structures. Bonded with phenolic resin these sheets are very durable and pos-
sess decay, insect and Žre resistant properties. BMCS has very high strength-to-
weight ratio and has great potential to be used as rooŽng material in place of as-
bestos cement corrugated sheets which have already been banned in many coun-
tries on environmental and health considerations. Apart from rooŽng, BMCS
has high use potential in wall panels, packaging, transportation, etc. The Insti-
tute is currently working in collaboration with BMTPC under a project funded by
the Ministry of Environment and Forests, Government of India for up scaling the
BMCS technology for commercialization. An Indian Patent has been applied for
jointly by IPIRTI and BMTPC (Application no. 653/ MAS /2001 dated 8th August
2001).
IPIRTI has collaborated with TRADA Technology of UK, under a project funded
by DFID, in design development of low-cost bamboo shelter using split bamboo
grid with cement plaster for walls, BMCS for roof with bamboo trusses, and BMB
for panel door/ window shutters. Under this project two demonstration structures
have already been constructed at Bangalore [12, 13]. High shear modulus of BMB
and BMVC can be advantageous in designing earthquake resistance houses [14].
122 A. K. Bansal and S. S. Zoolagud

3.1. Manufacturing process

The main raw material for making bamboo mat composites is the bamboo mat
woven from thin strips, 0.6 to 1.0 mm, of bamboo called slivers. Mat weaving is
done generally by women in rural/ tribal areas as a part-time vocation to supplement
family income. From bamboo splits, the epidermal layer is removed and slivers are
made and air-dried. Slivers are manually woven into mats of different sizes and
patterns. Herringbone is the most common weaving pattern in which slivers are at
±
an angle of 45 with respect to the edges of the mat.
Bamboo mats are dipped in phenol formaldehyde resin having speciŽc formula-
tion incorporating preservative chemical to enhance termite and decay resistance.
Resin coated mats are dried to a moisture content of around 10% either in drying
chambers or industrial dryers. Dried resin coated mats are assembled in 2, 3 or
5 plies and hot pressed to produce bamboo mat boards of desired thickness. For
thickness greater than 6 mm, bamboo mats can be interleaved with wood veneers.
Specially designed platens (matching dies) are used for making BMCS and moulded
articles. A generalized process ow chart is given in Fig. 1.

3.2. Product development

3.2.1. Bamboo mat board. Use of any new material depends upon its suitability
for various applications vis-à-vis the materials already in use. Development of
appropriate application technology plays an important role in acceptance of any
new material. BMB is essentially a layered composite comprising several layers

Figure 1. Generalized process ow-chart for bamboo mat-based composites.

 Bamboo composites: Material of the future 123

of woven mats having excellent internal bond strength, and are resistant to decay,
insects and termite attack. They have physical and mechanical properties at par with
waterproof plywood and are Žre resistant. Their mechanical properties depend upon
the material used for making mats, i.e. bamboo slivers, the weaving pattern and the
adhesive used for bonding.
Table 1 gives the strength properties of BMB made from some bamboo species as
studied at the Institute under the project ‘Wood Substitute (India)’ [15] sponsored
by IDRC, Canada. Unlike plywood that has cross-grain layers, BMB has mats with
herringbone weaving pattern arranged in the same direction with respect to weave
pattern. Stresses (tensile and compressive) applied along the length and width of the
±
board will be at an angle of 45 to the grain direction of the slivers. For this reason,
the strength of BMB in tension will be lower than the strength of round bamboo
along the length. It is for the same reason that tensile strength, modulus of rupture
(MOR) and modulus of elasticity (MOE) of BMB is lower compared to that of
structural plywood or wood (Table 2). It can also be seen from the Table 2 that the
speciŽc strength in bending (MOR=½ 2 , where ½ is the speciŽc gravity) and load-
bearing capacity in deection (MOE=½ 3 ) of BMB is lower than that for plywood
or wood, which is understandable from the fact that the speciŽc gravity of BMB
is comparable to that of plywood and wood. However, it has been observed that
±
strength of BMB in tension or bending at an angle of 45 to the length or the width
of the board is also higher than the corresponding strength along or across the board
length. Thus, it can be inferred that the strength and stiffness of BMB is related to
the weaving pattern of the mats.
However, modulus of rigidity (MORg) or shear modulus of BMB in the plane
of the board is very high and is comparable to the required values for structural
plywood as per Indian SpeciŽcations IS: 10701. It is interesting to note that MORg

Table 1.
Physical and mechanical properties of BMB from some Indian bamboo species

Property Bamboo species

[Average (standard deviation)]
Requirement Ochlandra Meloccana Bambusa Dendrocalamus
of IS: travancorica bambusoides bambose strictus
13598-1994
Density ( kg/ m3 ) 500– 900 770 (62) 700 (65) 890 (75) 800 (74)
Internal strength
(N/ mm2 /
Dry state 0.70 2.11 (0.24) 2.42 (0.26) 1.33 (0.11) 1.86 (0.16)
Wet state 0.50 1.97 (0.20) 2.14 (0.22) 1.10 (0.11) 1.42 (0.15)
Surface strength
(N/ mm2 )
Dry state 4.5 11.50 (1.62) 11.23 (1.50) 8.06 (0.80) 11.20 (1.30)
Wet state 3.0 11.40 (1.75) 10.47 (1.45) 6.05 (0.60) 8.40 (0.90)
124 A. K. Bansal and S. S. Zoolagud

Table 2.
Comparative mechanical properties of BMB, structural plywood and eucalyptus wood

Material SpeciŽc Tensile Modulus MOR Modulus MOE Modulus

gravity strength of rupture (½ 2 ) of elasticity (½ 3 ) of rigidity
(½) (N/ mm2 ) (MOR) (MOE) (MORg)
(N / mm2 / (N/ mm2 / (N/ mm2 /
BMB (3-layered) 0.75 22.7 (2.6) 50.7 (5.6) 90 3670 (400) 8700 5870 (695)
Structural plywood* 0.55 495 (75)
– along the grain 32.7 (6.6) 47.7 (8.6) 158 5690 (685) 34200
– across the grain 33.8 (6.4) 30.0 (4.8) 2560 (385)
Silver oak wood 0.53 51.5 (6.7) 61.5(2.8) 215 8100 (800) 54400 485 (48)
*
Made from Grewelia robusta (silver oak). (Figures in parentheses represent the standard
deviation.)

Table 3.
Potential applications of BMB and BMVC

Sector Applications
Housing Doors, partitions, paneling, cladding, concrete shuttering, rooŽng, ceiling
and structural uses
Packaging Packing cases for horticultural products like apple and mango, tea-chest
boxes, tobacco packaging cases, ammunition boxes
Storage and transport Grain storage bins (internal and external), cover for bullock carts and horse/
mule drawn carriages
Furniture Tables, cots, divans in combination with wood

of BMB far exceeds that of both structural plywood and wood. This is attributable to
the herringbone weave pattern. The ratio of MORg to MOE, which is around 0.6 for
wood, and 0.08–0.15 for plywood, exceeds 1.5 in the case of BMB. Clearly, BMB
has high in-plane rigidity and hence high racking strength and is more exible than
equivalent plywood. This property of BMB can be advantageously used in many
engineering applications. In fact BMB has been found to be especially useful as
sheathing material in structural and semi structural uses such as walling, partitions,
roof sheeting [16], door skins, box furniture, built up hollow beams, gussets,
containers [17]. Table 3 and Figs 4 – 9 show some typical end use applications of
BMB.
Investigations have also been undertaken at the IPIRTI regarding suitability of
BMB for manufacture of secondary parts of aircraft and gliders as substitute for
speciality plywood made from Dysoxylum malabaricum and Palaquim ellipticum.
BMB meet all the requirements prescribed in the relevant Indian speciŽcations and
have in fact much higher cross sectional shear strength compared to plywood [18].

3.2.2. Bamboo mat veneer composite. In BMVC, wood veneers are placed in-
between the layers of bamboo mats. The properties of BMVC depend upon the
 Bamboo composites: Material of the future 125

Table 4.
Physical and mchanical properties of BMVC

Sl. Property Structural BMVC* Plywood**

No. plywood 21 mm

1 Density (kg/ m3 / 750 800 (81.5) 553 (56.5)

2 Strength (N / mm2 /
(a) Tensile
Along the grain 54 36.4 (6.5) 32.7 (6.6)
Across the grain 34 35.8 (6.4) 33.8 (6.4)
(b) Compressive
Along the grain 34 43.9 (6.2) 24.5 (2.8)
Across the grain 29 40.2 (6.0) 20.5 (2.6)
3 Modulus of rupture (N / mm2 /
Along the grain 49 68.5 (7.8) 47.7 (8.6)
Across the grain 29 55.4 (6.6) 30.0 (4.8)
4 Modulus of elasticity (N/ mm2 /
Along the grain 7355 7820 (850) 5690 (685)
Across the grain 3923 3210 (485) 2560 (385)
5 Modulus of rigidity (N / mm2 / 588 3315 (505) 495 (75)
*
67% Grewelia robusta (silver oak) veneers and 33% bamboo mats.
** 7 ply, 16 mm made of silver oak veneers.

mechanical properties of wood veneers that are placed in between bamboo mat
layers, in addition to the properties of the bamboo mats and the adhesives used
in bonding. Investigations have shown that strength of a panel made by plantation
timber is substantially enhanced when made in combination with bamboo mats.
MOE and MOR of BMVC are higher than equivalent plywood and this depends on
the number of layers of veneers for a given thickness of BMVC (Table 4). Due to
the presence of woven bamboo mats, BMVC has different mechanical properties
along and across the length of the board. The properties are comparable to that
of structural plywood. Hence, for all practical purposes BMVC can be used in a
similar way to plywood for structural applications. As BMVC will be economical
in higher thickness as compared to BMB, BMVC may be advantageously used in
place of structural plywood.
Figure 2 depicts bar charts showing MOR, MOE, and MORg of BMB (both
herringbone and rectangular weaving patterns), BMVC (comprising 67% silver oak
veneers and 33% bamboo mat), and structural plywood (silver oak) along with
standard deviations.

3.2.3. Bamboo mat corrugated sheets. RooŽng materials such as asbestos

cement corrugated sheeting (ACCS), corrugated Žber reinforced plastics (CFRPs),
corrugated aluminum sheeting (CAS), corrugated galvanized iron sheeting (CGIS),
which have been established for more than several decades, are being subjected to
scientiŽc scrutiny on several counts, including their impact on workers’ health and
126 A. K. Bansal and S. S. Zoolagud

Figure 2. Comparative strengths of BMB, BMVC and structural plywood.

Figure 3. Comparative load– deection curves for BMCS, CGIS, ACCS and CAS.

environment, the energy requirement for their manufacture, and sustainable supply
of raw materials. Of late, priority is being given, and rightly so, to ‘green’ building
materials, based on renewable resources. Scaling-up of the pilot scale technology
for its industrial adoption is in progress under a project funded by the Ministry
of Environment and Forests, Government of India. The shape and area under the
load – deection curves (Fig. 3) of various corrugated rooŽng materials, namely,
BMCS, ACCS, CGIS, and CAS, clearly bring out the comparative advantage of
BMCS over other corrugated materials.
 Bamboo composites: Material of the future 127

3.3. Product standardization

Standardization of procedures for testing any material is a sine qua non to build up
consumer conŽdence and quality monitoring. Although bamboo mat composites
are similar to veneer plywood, conventional methods of testing strength properties
prescribed for plywood cannot be applied to these due to criss-cross sliver construc-
tion. Therefore, separate test procedures for BMB have been evolved based upon the
methods speciŽed for determining internal bond (IB) strength and surface strength
(SS) in IS: 2380. The Bureau of Indian Standards, the national standards body, has
already brought out the speciŽcation for BMB [19] and BMVC [20].

3.4. Economic feasibility of BMB production and extent of technology adoption

A techno-economic feasibility study of BMB manufacturing technology developed
at IPIRTI under IDRC sponsored project Bamboo Mat Board (India) was conducted
by the Institute in 1992 in collaboration with Institute of Socio-economic Change,
Bangalore. According to this study the beneŽt cost ratio to be 1.4 at 15% discount
rate [21]. In 1997, an independent evaluation of BMB technology was conducted
by the Agricultural Finance Corporation, Mumbai, India that has also found the
technology to be technically feasible and economically viable. According to this
study, a BMB unit with an annual production capacity of 129 000 boards (per shift)
of about 3 square meters and 3 mm thickness, requires capital investment of Rs.
16.85 million (US$ 0.38 million) and recurring expenses of Rs. 27.31 million
(US$ 0.62 million). Keeping the sale price at 20% lower than that of equivalent
plywood for market promotion, BC (beneŽt cost) ratio works out to 1.29 at 19%
discount rate. Such a factory is likely to generate about 0.20 million person-days,
mainly in mat weaving. It is estimated that if 25% of present plywood consumption
of 800 000 m3 were replaced with BMB, it would result in saving 8000 ha of forests
while generating employment to the tune of 35 million person-days particularly for
rural/ tribal women.
With regard to the cost–beneŽt analysis, if one looks at the investment and the
number of jobs created, it is revealed that there are not many other industrial
activities that provide so many jobs at such low investments. Three factories in
India, one each in the public, private and NGO sectors, are regularly producing
BMB. Two more industries in the private sector are being established for which
IPIRTI is providing the technology. The computed production capacity of the Žve
units will be around two million square meters of BMB per eight hour shift.
BMCSs produced at the pilot facility established at IPIRTI have been used
in several demonstration structures as mentioned above and establishment of an
industry is planned under a project funded by the Ministry of Environment and
Forests, Government of India.
Some important advantages of adoption of bamboo mat based technologies are
1. Reduced dependence on natural forests through wood substitution, thereby
contributing to protection of environment.
128 A. K. Bansal and S. S. Zoolagud

Figure 4. Panel door with BMB as panel inserts.

Figure 5. Grain storage bins made from BMB.

Figure 6. BMB-based curved roof.

Figure 7. Bamboo house constructed at IPIRTI, Bangalore (March 2001) using BMB for
door/ window shutters and BMCS for rooŽng (in collaboration with TRADA Tech., UK under a DFID
funded project).
 Bamboo composites: Material of the future 129

2. Creation of employment opportunities, particularly for rural/ tribal women.

3. Improvement of skills of people and enhanced earning capacity, leading to
overall welfare of society and particularly the economically weaker sections.
4. Bamboo is a very fast growing species and is suitable for rehabilitation of
degraded forest, other waste lands and shifting cultivated areas.

4. CONCLUSIONS
The BMB technology has attracted attention of a number of entrepreneurs and
few industries have already been set up in the country. However, positive policy
and technological initiatives are necessary to accelerate the use of bamboo mat
composites including encouraging their use in public sector where currently wood
is banned; development of application techniques for various end products; and
evolution of code particularly in housing, construction, transport; dissemination of
information about their utility through demonstration and exhibitions.
Considering the vast social and environmental implications and employment
potential, a policy thrust at national level is necessary for development of bamboo
resources in general and promotion of bamboo composites in particular. As a
Žrst step, Government has already given a favourable push by exempting bamboo
composites from excise duty. Eco-labeling of the products will also help promote
exports.
Every new technology for producing intermediate material requiring further
processing to manufacture end products requires continued R&D support during
its commercialization to solve problems which may come up during transfer of
technology from lab to factory. The technologies for BMB, BMVC, BMCS and
bamboo-based housing are no exception to this. In fact, they need such support
even more due to natural variation in the characteristics of the main raw material,
bamboo, associated with different species available in different areas / regions, and
different level of skills in bamboo mat weaving in various tribal / rural groups
traditionally weaving mats.

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